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Repairing the Sills
Rebuilding the Inner rockers
rust, anyone?
This is what was left of the front body mount and inner rocker on the left side. Before cutting all this out, I made sure to prop the body using jack stands so that it wouldn't "sag" or distort with the mount removed.
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ye olde rust worm
This is another view of the body mount and what is left of the inner rocker it mounts to.
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the replacement
I carefully drilled out the spot rivets on the body mount then formed this new inner rocker out of 18 gauge steel and welded the mount back on using the holes that I had drilled through it.
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fitting it back into the car
This is the view from under the car with the new rocker welded in and the body mount reattached to the frame. I did all the floor and inner rocker panels (in fact all the body work) with the body in position on the chassis to make sure everything stayed aligned and to prevent the body from twisting out of shape.
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Here it is from the top. I had to drill holes in the top of the mount to remove the floor pan. A spot weld cutter would also work. Here you can also see where I had to remove the lower portion of the door post where the lower hinge attaches. The lip on top goes under the lip of the upper sill and the floor pan is welded to it to tie everything together.
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